Unical PK 150 X 2S Installation And Servicing Instructions
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Unical PK 150 X 2S Installation And Servicing Instructions

Unical PK 150 X 2S Installation And Servicing Instructions

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PK 150 X 2S
PK 230 X 2S
PK 300 X 2S
PK 348 X 2S
INSTALLATION
AND SERVICING
INSTRUCTIONS
00334158 - 1
st
edition - 05/2012

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Summary of Contents for Unical PK 150 X 2S

  • Page 1 PK 150 X 2S PK 230 X 2S PK 300 X 2S PK 348 X 2S INSTALLATION AND SERVICING INSTRUCTIONS 00334158 - 1 edition - 05/2012...

  • Page 2: Table Of Contents

    Failure to follow the instructions indicated in this manual, which is supplied with the boiler, could cause injury to persons, animals or damage to property. UNICAL shall not be held liable for any injury and/or damage. CONTENTS 1 GENERAL INFORMATIONI ....................................3 1.1 Symbols used in this manual ..................................

  • Page 3: General Informationi

    Any other use of this appliance will be considered improper. UNICAL declines any responsibility for any damages or injuries caused by an improper use; in this case the risk is completely at the user’s responsibility. In order to use the appliance according to the scopes it was designed for it is essential to carefully follow the instructions indicated in this guide.

  • Page 4: Safety Warnings

    Servicing or repairs of the appliance must be carried out by UNICAL authorised service technicians; UNICAL recommends drawing up a service contract. Bad or irregular servicing could compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property for which UNICAL shall not be held liable.

  • Page 5: Data Plate

    General Information - The essential requirements of the Directive regarding gas 1.7 - DATA PLATE 2009-142 EC appliances (Directive The data plate can be found underneath the casing above - The essential requirements of the Directive regarding the first module's electrical box, a duplicate of the same 2004/108 EC electromagnetic compatibility (Directive data plate can be found on the control instrument's inside...

  • Page 6: General Warning

    Any repairs must be carried out by Unical authorized service Please read carefully the instructions contained in this ma- engineers and using only original spare parts. Non-obser-...

  • Page 7: Dimensions

    Technical features and dimensions TECHNICAL FEATURES AND DIMENSIONS 2.1 - TECHNICAL FEATURES - For boilers in battery (up to 7), control panel and electronic The PK series ... X is made up of gas heating units and very slave, external to the mantle, placed vertically at the side low condensing temperature according to dir.

  • Page 8: Technical Features And Dimensions

    Technical features and dimensions 2.2 - MAIN COMPONENTS AND FUNCTIONING The PKX boilers are built with a blind furnace, in which the burner's central flame travels towards the bottom and then is distributed in the flue pipes; at the terminal part of the pipes the combustion gas is collected in the flue chamber and then sent to the chimney.
  • Page 9 Technical features and dimensions 2.3 - DIMENSIONS 1 Control box T1 C.H flow Cable sheathing leads bulbs 2 Flame control sight glass T2 Average temperature system return Cable sheathing leads bulbs T3 Low temperature system return Chimney connection T4 Expansion vessel connection Burner connection T5 Boiler drainage T10 Condensate drain...

  • Page 10: Performance Data

    Technical features and dimensions 2.4 - PERFORMANCE DATA BOILER TYPE PK150X 2S PK230X 2S PK300X 2S PK348X 2S Boiler family gas category II 2H3P Nominal heat input on LCV Qn Minimum heat input on LCV Qmin Nominal heat output (Tr 60/Tm 80°C) Pn 136,5 209,2 273,6...

  • Page 11: Instructions For The Installer

    Instructions for the installer INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS The connection between the boiler and chim- AThis boiler has to be destined for the use for ney/flue outlet can be made only after this veri- which it has been expressively designed for. fication has been carried out.

  • Page 12: General Warnings

    Instructions for the installer INSTRUCTIONS FOR THE INSTALLER 3.1 - GENERAL WARNINGS 3.2 - STANDARD CODES FOR INSTALLATION AThis boiler has to be destined for the use for which it has been expressively designed for. This appliance must be installed in compliance to the manu- Any other use shall be considered improper facturer's instructions and and therefore dangerous.

  • Page 13: Packaging

    EBUS) rous. 00362324 (control panel "Slave") UNICAL refuses all liability for injury to per- sons, animals or damage to property deriving N.B. For models PK230X 2S the control panel is contained from not having respected the above mentio- ned recommendations.

  • Page 14: Handling And Lifting

    Instructions for the installer 3.4 - HANDLING AND LIFTING The boiler can be moved by lifting, via the holes or upper hooks. If necessary, due to the dimensions of the boiler, it is possible to remove the front door to facilitate the introduction in the boiler house.

  • Page 15: Boiler Location

    Instructions for the installer 3.6 - BOILER LOCATION The boiler must be installed in accordance with the relevant requirements of the Gas Safety Regulations, current I.E.E. Regulations, local water authority by e-laws and it should also comply with any relevant requirements of the local gas sup- plier, local authority and the relevant Standard Codes of Prac- tice and building regulations.
  • Page 16 Instructions for the installer Chimney dimension Flue Gas Temperature 40°C DIN 4705 Pressure avaible 40 Pa Flue gas Co level mass rate kg/h kg/s 2520 0,700 1037 1400 1400 2160 0,600 1200 1200 d 400 1800 0,500 1000 1000 1440 0,400 1260 0,350...
  • Page 17 Instructions for the installer 3.8 - CONDENSARE DRAIN The condensate drain system must be: built in order to prevent the products of combustion di- To maintain proper flow of condensate the drain pipe must scharging in the ambient or in the sewage(siphon); have an inclination toward the drain of at least 30 mm/m sized and built so as to permit the correct flow of the liquid (3/8 in./ft).
  • Page 18 Instructions for the installer 3.9 - FIRE DOOR: ADJUSTMENT,OPENING & CLOSING IMPORTANT - The door must be opened only when the boiler is cold to avoid causing damages to the fibre lining due to thermal stress. - The door's fibre lining can crack after a brief period of boiler operation;...

  • Page 19: Gas Conection

    As a safety measure against gas leaks, eliminated. Unical recommends installing a surveillance Never look for gas leaks using a naked flame. and protective system composed of a gas leakage detector combined with an on-off selenoid valve fitted on the gas supply line.

  • Page 20: System Connection

    Instructions for the installer 3.11 - SYSTEM CONNECTION WARNING! WARNING! Before connecting the boiler to the heating IT IS ABSOLUTELY FORBIDDEN TO FIT ON- system we recommend that the system is OFF VALVES ON THE BOILER BEFORE THE flushed out with a suitable product in order to SAFTEY DEVICES eliminate any metallic tooling or welding residues, oil and grime which could reach...

  • Page 21: Determination Of Primary Circuit Pump Or Boiler System Pump

    Instructions for the installer 3.12 - DETERMINATION OF PRIMARY CIRCUIT PUMP OR BOILER SYSTEM PUMP The size of the pumps must be determined The boiler pump must have a delivery head which can by installers or technical engineers accor- ensure the water flow rate as shown in the graph "Water ding to boiler data and system design.
  • Page 22 Instructions for the installer Perdita di carico lato acqua PK230X 2S WATER SIDE PRESSURE LOSSES 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 32000 34000 36000 38000 Q : portata acqua (l/h) water flow rate (l/h) Perdita di carico lato acqua WATER SIDE PRESSURE LOSSES...

  • Page 23: Frost Protection

    Instructions for the installer Perdita di carico lato acqua PK348X 2S WATER SIDE PRESSURE LOSSES 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 Q : portata acqua (l/h) water flow rate (l/h) 3.13 - FROST PROTECTION If the flow temperature (measured at global flow NTC) falls WARNING: below 7°C, the system pump circulates water around the If the boiler has remained unused for a long...

  • Page 24: Water Treatment

    Instructions for the installer 3.15 - WATER TREATMENT To minimize corrosion it is essential to use a scale inhibitor, however in order for this to function correctly, the metallic The chemical-physical characteristics of the filling water and surfaces have to be clean. reinstatement water in heating systems are of fundamental importance for guaranteeing correct and safe boiler operation.

  • Page 25: Casing Assembly

    Instructions for the installer 3.16 - CASING ASSEMBLY C. Fit the self-tapping screws onto the internal profiles of the 2 side panels (4 and 5 ). (con pannello comandi montato a destra) A. Fit the insulation blanket (1) onto the boiler shell and secu- re in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation.
  • Page 26 Instructions for the installer E. After removal of the two side screws from the control panel F. Fit the right hand side panel (5) to the lower panel and fix it rotate its cover towards the front to the upper squadretta on the right hand side of the boiler body, inserting the lower bend inside the bottom L profi- les.
  • Page 27 Instructions for the installer Guide the burner plug through the side cable clamp pla- H. Fit the top panel (8) and fix it onto the side panels (4 & 5). te(6) and clamp the cable using the cable clamp sup- plied.
  • Page 28 Instructions for the installer M. Fit the lower right hand side rear panel (11) onto the right O. Position the top panels (14 and 15) and press them hand side rear panel (5), to the left hand side rear panel against the side panels.
  • Page 29 Instructions for the installer R) after removing the cover disconnect the connector "4", un- U) plug the connector "4" on the unit, screw the 2 nuts "5" and remove the bracket "6", V) replace the cover "2" access to the terminal unit, and se- cure with the two screws "1".
  • Page 30 17. during normal boiler operation. This tap must NEVER be used for draining of the whole UNICAL refuses all liability for injury to system as this could lead to system dirt gathering in the persons, animals or damage to property boiler, compromising good boiler operation.

  • Page 31: Electrical Connections

    WARNING! We remind you that upstream of the electrical UNICAL refuses responsibility for any damages arising from connection, it will be necessary to foresee a failure to earth the boiler correctly. service relay (NOT SUPPLIED) which, when...

  • Page 32: Outdoor Sensor Connection

    Instructions for the installer Outdoor sensor connection Single boiler Gain access to the rear of the eBus and remove the DANGER! terminals numbered from 5 to 11. Switch off and disconnect the electricity sup- ply before carrying out any operations on the Outdoor sensor connection: insert the cables between electrical parts.

  • Page 33: Pump Connection

    Instructions for the installer Pump Connection Single Boiler - For the fixed flow rate pump connection, place the ca- FIXED RATE PUMP bles between pin 1.2 and terminal M1. MARRONE MARRONE GIA/VER GIA/VER Boiler battery Modulating Pump The BCM (optional kit) board, elaborates the data con- cerning the thermal drop (Δt between primary flow and return) and provided power.

  • Page 34: Functional Low Wiring Diagram

    Instructions for the installer 3.19 - FUNCTIONAL FLOW WIRING DIAGRAM E.ACC = Ignition electrode E. ACC E.RIV = Ionization electrode = Main switch = Flue switch = Gas switch = CH sensor = CH return sensor = Condensate level sensor = Limit thermostat TR.ACC = Ignition transformer = Gas valve...

  • Page 35: Types Of Installation

    Instructions for the installer 3.20 - TYPES OF INSTALLATION Single boiler Boiler Cascade Control panel Control panel fitted with an fitted with an eBus heating eBus heating controller controller Slave Panel BCM cascade manager (kit 00361602)
  • Page 36 Instructions for the installer Electrical connections for boilers installed in a cascade formation The cable for the connection between the boiler and the BCM must have the following EBUS UNIT characteristics: PVC HT CABLE 3x0,5 eBUS + eBUS - 5 6 7 8 9 10 11 BOILER 1 NERO remove the...

  • Page 37: Installation Examples

    Instructions for the installer 3.21 - INSTALLATION EXAMPLES (Functional diagram) Boiler connection to the heating system, with 1 direct high temperature heating zone CH SYSTEM HIGH TEMPEARTURE EXPANSION VASSEL BOILER SENSOR BOILER PKX NB: In case of a single system return (low or medium temperature), the connection must ALWAYS be carried out on the inlet and the lower back of the boiler (stub "low-temperatu-...
  • Page 38 Instructions for the installer...

  • Page 39: Initial Lighting

    UNICAL shall not be held liable for any Hand over to the person in charge of the appliance the injury and/or damage.

  • Page 40: Burner Pressure Adjustment

    MAXIMUM OUTPUT ADJU- STMENT SCREW WARNING! All the instructions indicated below are for the exclusive use of qualified UNICAL service tech- B) Min output adjustment nicians or installers. All the boilers are supplied already calibrated Via the e-bus controller change the "Test" mode and run and tested.
  • Page 41 (refer to procedure indicated WARNING! on page xx). All the instructions indicated below are for the exclusive use of qualified UNICAL service te- Check that the percentage of C02 is within the values chnicians. indicated in the table "Burner pressures"...
  • Page 42 Instructions for the installer B) Min output adjustment MINIMUM OUTPUT ADJU- STMENT SCREW Via the e-bus controller Change the "Test" mode and run the boiler at minimum output (refer to procedure illustrated on page 43). Check that the C02 values are within the values indica- ted in the table "Burner pressures"...
  • Page 43 Instructions for HSCP calibration/adjustment 3.25 - ACTIVATION CHIMNEYSWEEPER MODE Turn the knob C Press key A (store) Turn the C until "Manual control" appears on the display. For activating the "CHIMNEYSWEEPER MODE" proceed as follows: Press key B (menu) Select the activation command of the function Turn the knob C until the symbol appears...
  • Page 44 Instructions for HSCP calibration/adjustment 3.26 - PROGRAMMING THE OPERATOR PARAMETERS ATTENTION! OPERATIONS TO BE CARRIED OUT ONLY BY TECHNICIANS TO VERIFY AND MODIFY (IF REQUIRED) THE OPERATING PARAMETERS Press key A (2nd zero) appears on the display Press key A (3rd zero) appears on the display Press key A (4th zero) appears on the display...
  • Page 45 Instructions for HSCP calibration/adjustment DEFAULT SETTINGS Position Identification Parameter description PKX 150 PKX 230 PKX 300 PKX 348 CH: Minimum Setpoint CH: Maximum Setpoint Pump: Overrun System Config. (single master) System Config. (master in battery) System Config. (slave) Ignition modulation Standby modulation Maximum Modulation Minimum Modulation...

  • Page 46: Inspection And Maintenance

    Unical spare parts must be used. Yearly maintenance of the appliance is man- datory in compliance with Laws in force.

  • Page 47: Boiler Body Maintenance

    Inspections and maintenance Checking status of gaskets and insulation fibres Boiler body maintenance The insulation fibre of the door can show Danger! cracks after a short time of operation; this howe- Before performing any maintenance, make ver does not reduce its insulation capacity nor sure the boiler and its components have co- jeopardise its lifespan.

  • Page 48: Error Codes

    Error codes ERROR CODES 5.1 - ERROR CODES DISPLAY Reset key Failure notification Error description Error code Error codes of EBUS control unit are indicated below together with its meaning and corrective actions. Code: Meaning: Code: Meaning: Insufficient gas pressure Sanitary sensor failure (only if the boiler is cou- pled with an outer storage tank) Solution:...
  • Page 49 Error codes Code: Meaning: Code: Meaning: Excessive water temperature detected by the Safety thermostat intervention (TL) heating sensor (SR) (> 95°C) Solution: Press the unblock key on the panel Solution: Check water circulation in installation Code: Meaning: Heating system failure (SR) Code: Meaning: Loss of the flame signal during operation...
  • Page 52 46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - telefax 0376/660556 www.unical.ag - info@unical-ag.com Unical will not be held responsible for possible inaccuracies if due to transcription or printing errors. It also reserves the right to modify its products as deemed necessary or useful, without jeopardising their essential features.

This manual is also suitable for:

Pk 230 x 2sPk 300 x 2sPk 348 x 2s

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